AUTOMATIC TRANSMISSION REPAIR ON CUSHMAN 660 ENGINE SERVICE MANUAL (1)

SERVICE MANUAL AUTOMATIC TRANSMISSION REPAIR ON CUSHMAN 660 ENGINE Part No. 844739 Rev. B

Table of Contents Section 2B2

Automatic Transmission Outline ................................................................................. 2B2-2 Clutch and brake operation .............................................................. 2B2-4 Operation list of primary elements ........................................................ 2B2-4 Power transmission pathway ............................................................ 2B2-5 Valve functions ........................................................................ 2B2-8 Shift Solenoid .......................................................................... 2B2-8 Oil hydraulic circuit ..................................................................... 2B2-9 Gear box specifications ............................................................... 2B2-18 Shift mechanism ..................................................................... 2B2-19 Failure diagnostics .................................................................... 2B2-24 Vehicular tune-up ..................................................................... 2B2-27 AT oil exchange ...................................................................... 2B2-28 Oil pressure test ..................................................................... 2B2-28 Stall test ............................................................................ 2B2-29 Time lag test ........................................................................ 2B2-30 Traveling test ........................................................................ 2B2-31 P Range test ........................................................................ 2B2-32 Shift lever switch ..................................................................... 2B2-32 Speed Sensor ....................................................................... 2B2-33 Throttle sensor ....................................................................... 2B2-34 Shift solenoid ........................................................................ 2B2-35 D range idle up ...................................................................... 2B2-35 Troubleshooting ...................................................................... 2B2-38 Analysis .............................................................................. 2B2-40 Unit analysis ......................................................................... 2B2-49 Subassemblies analysis ............................................................... 2B2-56 Servicing/Repair material list ............................................................ 2B2-83 Special tools list ....................................................................... 2B2-83

100-6-01-CU

©2001 Textron Inc. Lincoln, Nebraska • All Rights Reserved.

Printed in U.S.A.

Outline 2b2-1

Automatic Transmission Identification Numbers

Automatic transmission identification numbers are located as shown below.

Automatic Transmission 2B2-2 Summary

Liquid torque converter and electronic advance control with three stages, and a separate reverse stage.

Torque converter

Parking lock gear Bulb body

Oil pan

Page 28 Automatic Transmission 282-3 Item

Torque converter Style stall torque ratio Uil pump Style Driving system Gear Ratio

Model 3 Main 1 stage 2 phase 2.30 Trochoid torm oil pump Engine drive

Style

Simpson type planetary tooth wheel form Advance Three stage Reverse One Stage

Shift position

P Range: Gearbox neutral, output axis, engine starting R Range: Reverse gear N Range: Gearbox neutral, engine starting D Range: Advance, low gear«2nd gear«high gear; automatic shift 2 Range: Advance, low gear«2nd gear-,high gear; automatic shift L Range: Advance, low gear-, 2nd gear; fixed low gear Front sun gear toothed wheel ....................... 37 Rear sun gear toothed wheel ....................... 27 Front pinion toothed wheel ......................... 16 Rear pinion gear .................................. 17 Front internal gear toothed wheel .................... 69 Rear internal gear toothed wheel .................... 6 0

GEAR RATIO 1st gear(Low) ........ 2.727 2nd gear(Second) .... 1.536 3rd gear(top gear) .... 1.000 Reverse gear ........ 2.2 2

Main Control

Primary Deceleration Ratio Final Reduction Ratio Lubricating Lubricating method Cooling Cooling method Recommended Oil

Wet type multiple disk clutch .......... 2 sets Band type brake .................... 1 set Wet type multiple brake .............. 1 set One way clutch ..................... 1 set 6.142 Oil Pump transfers forced pressure Radiator cooling support (cold water) Suzuki ATF 5D06

Page 29 Automatic Transmission 282-4

Clutch Operation Item Name

Direct clutch Forward clutch Second brake band First reverse brake One way clutch

Function Input shaft rotation transmitting to sun gear or cutting off .

Input shaft rotation transmitting to front internal gear or cutting off.

Fixed or opens sun gear.

Fixed or opens rear planetary carrier.

Keeps rear planetary carrier fixed.

Operation List of Primary Elements Element

Shift Position

p R N D D D 2 2 L

Direct Clutch

Forward Clutch

-

-

Engaged

1st Gear 2nd Gear 3rd Gear 1st Gear 2nd Gear 1st Gear

Disengaged

Second Brake Band

-

Disengaged

First Reverse Brake

-

Engaged

-

-

-

-

Disengaged Disengaged Engaged Disengaged Disengaged Disengaged

Engaged Engaged Engaged Engaged Engaged Engaged

Disengaged Engaged Disengaged Disengaged Engaged Disengaged

Disengaged Disengaged Disengaged Disengaged Disengaged Engaged

Automatic Transmission 282-5 Transmission Operation Process

----

DV2 Range 1 Speed

Forward clutch

Rear planetary gear

\

Internal gear

The oil passes over the forward clutch . Then the input shaft and the front planetary gear's internal gears are together in gear union. Because of that gear union, the input shaft's rotation is passed on directly to the internal gears. From the front planetary carrier to the output shaft, the rotation is passed on in the right direction. On the other side, the pinion of the front planetary gear and the sun gear engage each other. The sun gear rotates in the left direction and the sun gear's rotation passes on to the pinion of the rear planetary gear. Because the sun gear rotates left and the link between the sun gear and the pinion, the rear planetary gear tries to rotate left but the one way clutch obstructs the rotation. The pinion gear has to spin to the right instead. The internal gear of the rear planetary gear rotate in the right direction and pass the rotation on to the output shaft in the right direction.

DV2 Range 2 Speed

The oil passes over the forward clutch . Then the input shaft and the front planetary gear's internal gears are together in gear union. Because of that gear union, the input shaft's rotation is passed on directly to the internal gears. From the front planetary carrier to the output shaft, the rotation is passed on in the right direction. On the other side, the pinion of the front planetary gear and the sun gear engage each other. The sun gear tries to rotate in the left direction but the second brake grips it into a fixed state so it can not turn.

The pinion of the front planetary gear revolve around the sun gear. The front planetary gear turns in the right direction and the output also turns in the same direction.

Automatic Transmission 2B2-6

DV Range 3 Speed

Output shaft

Oil passes over the forward clutch and the direct clutch. The input shaft is connected to the front planetary gear's internal gear and the sun gear. The input shaft directly connects to the planetary gear unit itself. The pinion of the front planetary gear locks into a stationary status. In that situation the input shaft rotation passes on to the output shaft.

LV Range 1 Speed

Output shaft

The rotation passing in D and 2 range is the same as in low gear, but when the rear planetary carrier is obstructed by the engine brake, it turns to the right direction and the oil pressure spreads to the first reverse brake and then fixes the rear planetary carrier in a stationary position. When driving in D range, the one way clutch action obstructs the rear planetary carrier's left directional rotation. The engine brake output shaft's action is not affected by the one way clutch because the output shaft rotates to the right. The one way clutch has no effect.

The rear planetary carrier will be racing. It will be necessary to activate the first reverse brake, fix the rear plane­ tary carrier, and engage the strong engine brake.

Automatic Transmission 2B2-7

RV Range Rear planetary gear

\

--

First reverse brake

The oil passes over the direct clutch. Then the input shaft and the planetary gear's sun gear are connected in gear union. The input shaft's rotation is directly passed on to the sun gear. In the case where the first reverse brake is applied, the action will affect the rear planetary carrier. The rear planetary carrier will affect the pinion gear. The pinion gear will spin by itself but will not revolve. (In this case, the difference between spin and revolve is that spin is referring to a twisting in place, revolve is referring to orbiting like planets around a sun.)

The output shaft fits into the internal gear. It rotates in the left direction and reverses the vehicle.

NVP Range Parking lock gear

Parking lock cam

Parking lock ball

Because of the forward clutch and the direct clutch release, the input shaft rotation is not passed on. In the P range the output shaft counter drive gear and the parking lock gear become united. That causes the parking lock pole to engage in the parking lock gear.

Then the back wheel is mechanically locked.

Automatic Transmission 2B2-8 Valve Functions Valve Name Manual Valve

Pressure Regulator Valve 1 -2 Shitt Valve 2 -3 Shitt Valve

Low cost modulator valve

solenoid Number 1 solenoid Number 2

Function Line pressure distributed to proper section positions in each circuit.

Adjusts slot pressure for proper pressure for traveling.

1 - 2 speed gear shitt.

2 - 3 speed gear shitt Adjusts line pressure to relieve shock in Range L. Puts line pressure on 2 - 3 shitt valve.

Puts line pressure on 1 - 2 shitt valve.

Shift Solenoid Solenoid Number 1 , Number 2 The Shift Solenoids, solenoid number 1 and 2, are attached to the valve body of the transmission. The AT control sends an ON or OFF signal to each of the gears as needed and regulates gear shift control.

Solenoid Operation Cases Bottom Chart Grid Labels (Top to Bottom):

Shift Position Gear Position Soft Solenoid Number 1 Soft Solenoid Number 2

0: ON ( carrying current; electric charge passing through) X: OFF (not carrying current; no electric charge passing through) In regards to (3) and (2), operation shown is only for the time of down shifting.

Automatic Transmission 2B2-9

Oil Pressure circuit N Range (P Range is the same).

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When the engine starts, the oil pump starts rotating. The oil pressure regulator valve regulates the valve that provides oil pressure. Then it is passed on to the torque con­ verter. From the pressure regulator valve, line pressure closes the circuit using a manual valve. That is why neither the clutch nor the brake have an effect on the oil pressure.

Automatic Transmission 2B2-10

DV2 Range 1 Speed

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Pressure on the regulator valve regulates the line pressure. The line pressure passes through the manual valve and affects the 1-2 shift valve. (Solenoid Number 2 OFF means closed. Solenoid Number 1 means open). Line pres­ sure does not affect 2-3 shift valve. Therefore, the oil pressure affects the forward clutch and switches into low gear.

At this time, line pressure affects accumulator number 1 and also functions to relieve the shock that is produced when the clutch connects.

Automatic Transmission 2B2-11

DV2 Range 2 Speed

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When the vehicle gets to second gear, solenoid number 2 is ON providing line pres­ sure relief. Therefore, line pressure passes through the 1-2 shift valve. The line pres­ sure affects the second brake piston. At this time it affects accumulator number 1 and 2 and also functions to relieve the shock that is produced when the clutch connects.

Automatic Transmission 2B2-12

DV2 Range 3 Speed

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When third gear is reached, solenoid number one is OFF and line pressure passes through the 2-3 shift valve and affects the direct clutch. At this same time, line pressure changes to back pressure and affects the second brake and pushes back the second brake piston. Then third gear will be reached.

Automatic Transmission 2B2-13

L Range

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Line pressure passes through the manual valve and affects the forward clutch. On the other side, line pressure passes through the 2-3 shift valve. The low cost modulator valve adjusts that pressure.

That pressure passes through the 1-2 shift valve and affects the first reverse brake.

Automatic Transmission 2B2-14

R Range

Line pressure passes the manual valve and affects the direct clutch. On the other side, the line pressure passes through the 1-2 shift valve. That line pressure affects first reverse gear.

Automatic Transmission 2B2-16 Throttle Sensor -- (1) Red

+

The throttle sensor is attached to the carburetor throttle valve shaft and the degree of opening is signaled to AT control.

---100%

--@® ---0 % .....___ (3) Black -

/

Car Speed Sensor The pulse generator system detects the output shaft's rotation inside the transmission case.

This pulse generator detection is done without any point of contact sensor. The pulse generator is comprised of a perma­ nent magnet, rotor and coil. The parking gear is attached to the output shaft. This parking gear starts to rotate. From the permanent magnet, a magnetic induction flux field is pro­ duced. As the magnetic flux changes, the coil gear's rotation is directly proportional to the frequency of the voltage. This voltage enters the AT control and the control module mea­ sures and determines the rotation of the output shaft. In effect, the control module is able to distinguish the car speed.

Automatic Transmission 282-17 Shift Switch The lever positions for shifting are P and N only. The engine can only be started in P and N. This is the way the switches are set up.

Terminal Number Color

1

2

Black&Red

Black&Yel- Yellow low

Switch Position

p

R N D 2 L

3

X

X

X

X

4

5

6

Red

Black

Green Green &Red & white

X

X

7

8

X

X

X

X X

X X

X

Blue& White

X

Fuel Saving Function There are some cases where problems may develop with the shift solenoid and the car speed sensor. Even when those types of problems occur, there are mechanical safety backup systems set up to ensure safe driving. In the following chart, the situations of both normal and malfunctioning units are compared for gear shift positions.

Status Shift Position D

2

L

Normal Condition

Shift Solenoid No. 1 Abnormal

Shift Solenoid No. 2 Abnormal

Shift Solenoid No. 1& 2 Abnormal

1st 2nd 3rd 1st 2nd (3rd) 1st 2nd

3rd 3rd 3rd 3rd 3rd 3rd 1st 2nd

1st 3rd 3rd 1st 3rd 3rd 1st 1st

3rd 3rd 3rd 3rd 3rd 3rd 1st 1st

Automatic Transmission 2B2-18

Gear Special Features D, 2 Range and L Range gear speeds are dependent on the throttle opening. The diagram below illustrates how the amount that the throttle is opened affects the vehicle speed. a-e

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Vehicle speed (km/hr)

60

70

Automatic Transmission 2B2-19

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D D D D DL -' p

R N

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Shift Mechanism Select Pattern Push the select lever to operate.

Because of the high frequency of use, the shift lever is set up for the N and D range gears to function as free release or free select.

Leave the select lever in that position.

Idle up Mechanism Traveling range gear settings (all gear settings except P and N) can either idle up or idle stably.

The idle up actuator is shared with the electric load actuator.

Idle up actuator.

Automatic Transmission 2B2-24

Diagnostics T R A N

s

M

I

s s I 0 N

Status of situation Oil level is low.

Transmission Case has oil leaking out of its joints.

Oil leaking from transmission case.

Low oil pressure.

Oil pressure high.

Probable presumed causes -Oil is leaking from oil filler tube.

Treatment Refill oil to standard recommended level.

There appears to be oil leaking.

-Oil level too high.

-Breather hose is broken.

Gasket O- Ring Seal Ring -Manual select shaft oil seal

Repair Refill oil to standard recommended level.

Repair hose.

Exchange Exchange Exchange Exchange

Oil pan gasket Oil filler tube O-Ring Oil pressure gauge plug Electric connector O-Ring -Oil level low.

Oil pump strainer plugged up.

Change Gasket.

Change O-Ring.

Tighten plug.

Exchange.

Refill oil to correct level.

Rinse out strainer.

Oil pressure circuit leaking.

Overhaul.

Pressure regulator valve ruptured or in bad condition.

Pressure regulator valve.

Overhaul the valve body.

Overhaul the valve body.

Automatic Transmission 282-25

s

T A R T I N G

Status of situation Impossible to move vehicle in any of the gear ranges.

Oil Pump worn out.

Oil Pump burned out.

Regulator valve sticking.

Oil strainer clogged Planetary gear burned or damaged.

Oil pump bushing worn out causing an oil pressure leak.

Input shaft seal ring worn out or damaged causing an oil leak.

Torque converter internal parts in poor condition.

Manual valve in poor condition.

Treatment Bring oil level back to standard range.

Exchange Exchange Exchange Wash strainer.

Repair or exchange Exchange Exchange Exchange

D and 2 range not functioning. Traveling in 1st gear only and slipping easily.

Oil pump bushing worn out causing an oil pressure leak.

Input shaft seal ring worn out causing an oil pressure leak.

Forward clutch slipping.

One way clutch poor condition.

Exchange

Impossible to travel in L range. Slipping easily.

Oil pump bushing worn out and causing an oil pressure leak.

Input shaft seal ring worn out or damaged causing an oil pressure leak.

First reverse brake disk slipping.

First reverse brake piston 0-ring damaged.

Oil pump seal ring worn out or damaged causing oil pressure leak from the direct clutch.

Direct clutch bushing worn out.

Direct clutch worn out.

Regulator valve sticking.

Second brake band poor condition.

Second brake piston seal ring damaged.

1-2 shift valve sticking.

Shift solenoid Valve Number 2 sticking.

Exchange

Impossible to travel in R range. Slipping easily.

GEARSHIFT

Probable presumed causes AT Oil shortage

1-2 Gear shift change performing poorly. Slipping easily.

Exchange Exchange Exchange

Exchange Exchange Exchange Exchange Exchange Exchange Exchange Exchange Exchange Exchange Exchange

22

Automatic Transmission 282-26 G

e a r

Status of situation Poor shifting from 2®3 gear ranges. Slipping.

s

h i f t

D range starting poorly and acting jerky.

R range starting poorly.

Shuddering.

Big shock when shifting from 1 ®2 gears.

Big shock when shifting from 2®3 gears.

NOISE

Big shock when shifting from N®D. Funny, rumbling noise sounding like "gattagatta" Funny noise sounding like "jajaja" P-N range noise

Probable presumed causes Oil pump cover seal ring worn out or damaged causing direct clutch oil pressure leak.

Direct clutch bushing worn out.

Direct clutch slipping.

2-3 shift valve sticking.

Shift solenoid valve No. 1 sticking.

Direct clutch piston check ball gripping foreign object.

Treatment Exchange

Regulator valve sticking.

Oil pump bushing worn out causing forward clutch oil pressure leak.

Input shaft seal ring worn out or damaged causing forward clutch oil pressure leak.

Forward clutch functioning poorly.

Oil pump cover seal ring worn out or damaged causing direct clutch oil pressure leak.

Direct clutch bushing worn out.

Regulator valve sticking One way clutch poor condition.

Accumulator second brake piston poor condition.

Regulator valve sticking.

Second brake piston poor condition.

Accumulator forward clutch piston poor condition.

Oil pump bushing worn out and causing an oil pressure leak from the forward clutch.

AT oil shortage

Exchange

AT oil shortage Oil pump worn out.

Exchange Exchange Exchange Exchange Exchange

Exchange Exchange Exchange Exchange Exchange Exchange Exchange Exchange Exchange Exchange Exchange Exchange Bring oil level back up to standard level.

Bring oil level back up to standard level.

Exchange.

Automatic Transmission 2B2-27 Vehicle Maintenance and Servicing

Inspection

Before analyzing the automatic transmission, first do a vehicle test. Find and isolate the problems and what is causing them. Then, make the decision whether an automatic transmission analysis is called for. If you do not check carefully for the factors causing the problems, you can create additional new problems besides the one you started with and also waste time.

The traveling problems experienced when the automatic transmission is in poor condition can be grouped into the following classifications: 1. Inspection when adjustments were made was not appropriate.

2. The engine is performing poorly.

3. Oil pressure control mechanism is in poor condition.

4. Electronic control system is in poor condition.

5. The transmission is in poor internal, mechanical condition.

When users bring vehicle for servicing, the service providers need to carefully ask questions to determine which general classification group of problems the symptoms seem to point to. Depending on the responses of the user, the service provider may choose the appropriate group of tests and remedies.

Appearance Review Test

Check the AT oil condition for

Standard Inspection: amount and purity.

Adjust the manual selector cable.

I

I

Stall Test:

I

Time lag test:

Oil Pressure test:

Forward clutch, second brake, first reverse brake wear and oil pressure condition.

Engine performance Torque converter poor condition Forward clutch, first reverse brake slipping or not

Regulator valve condition Line pressure: leaking oil or not.

I

I Inspect for oil leak.

Service provider can do a general visual check and examine the gaskets and oil seal for leaks.

I

Vehicle maintenance

I Analyze the transmission.

I

AT Controller inspection

Automatic Transmission 2B2-28 .---------------------, AT Oil Exchange 1. When the engine cools down, take off the oil band's oil plug and let the oil drain out.

Oil should be changed every 4000 km traveled.

2. After the oil is drained out, the oil should be replaced through the oil filler tube with the same amount of oil up to the appropriate level. The oil should be the recommended type. Start the car and let it idle until the car warms up.

Move the transmission select lever through each of the settings and then check the oil level again. If the oil level is below the recommended amount, refill with additional oil to bring the level up to the recommended amount.

Oil Capacity (1) Time of Oil Change

0.8

Time of Overhaul

2.7

AT Oil: Suzuki ATF 5D06 Oil drain plug tightening torque: 180 - 270 kg · cm

Oil Pressure Test

Measure the oil pressure in the oil pressure line.

Then inspect each of the functions during operation.

1. Attach an ATM oil pressure gauge to the spout of the transmission case.

Special Tool:

(A) ATM Oil Pressure Gauge: 09925 - 37810 2. Prevent the wheels from moving. Pull up the side brake all the way.

3. Step on the foot brake and bring the engine to idling and stall status. Then measure the oil pres­ sure in the D and R ranges.

Engine Running Status

Oil Pressure (kg/cm) D Range

R Range

Engine Idling

5.5 - 6.6

12.5 - 15.7

Engine Stalling

5.8 - 6.6

12.8 - 15.7

Notice: After attaching the oil pressure gauge, make sure to check for leaking oil.

Oil temperature should be normal traveling temperature (70-80° C).

Do not continue the stalling test more than 5 seconds.

Automatic Transmission 282-29

Main Evaluation Points

Test Results Oil Pressure higher than standard pressure in each range.

Oil Pressure lower than standard pressure in each range.

Oil Pressure lower than standard pressure in D range.

Oil Pressure lower than standard pressure in. R range.

Probable presumed causes Regulator Valve not functioning properly.

Oil pump not functioning properly.

Regulator Valve functioning poorly.

Oil leaking from forward clutch.

Leak in oil circuit in the D Range.

Direct clutch leaking oil.

First-Reverse brake is leaking oil in the R range.

Stall Test Measure the engine's maximum rotation number for each gear range and check the general performance of the automatic transmission and engine.

1. Be sure to block off the front and back wheels securely so the car will not roll. Hold the foot brake down.

2. Connect the engine revolution counter.

3. Start the engine.

4. Move the select bar to the D range. Step on the accelerator and watch the engine revolution measurement (rpms) as the degree of acceleration is increased. Then get the revolution number (rpms) to hold constant at the standard stall point and take a quick measurement reading of the engine (revolution number at stall point).

5. Perform the same test procedure in the R range.

Stall Revolution range numbers: Note:

D range 2550 - 2850 rpm

R range 2550 -2800 rpm

This test should not be continued for more than 5 seconds because the oil temperature will rise too high.

This test should be done when the engine is already warmed up. Once this test has been performed, leave the engine idling for at least 30 seconds.

Automatic Transmission 282-30 Main Eval- Sy mptoms uation Points

Causes

Lower than standard value D range higher than standard value.

R range higher than standard value.

engine generator in poor condition. torque converter in poor condition.

Forward clutch slipping Starter one way clutch not performing properly.

Direct clutch slipping FirsVreverse brake slipping Oil pressure is low.

Starter one wav clutch not oerformina orooerlv.

Time lag test With the engine idling and revolving, shift the gear select lever. Measure the time lag between the time of shifting the lever and the time that the shock or jolt is felt, indicating that the gear has changed. Then check the oil pressure of the clutch and the reverse brake.

Note: This test should be done again with an interval of more than 1 minute in between testings. The gear should be in the N position between tests. This test should be performed when warm.

1. The front wheel and back wheel should be blocked securely. The foot brake should also be held down.

2. Start the engine.

3. Shift the select lever from the N to the D position. At this time, measure the time of the shock with a stop watch.

4. Use the same process with N to R positions.

Time lag standard values:

Main Evaluation Points

N®D N®R

0.7 seconds or more 1 .2 seconds or less

Test Results N®D time exceeds standard time.

N®R time lag exceeds standard time.

Probable presumed causes Oil pressure is low.

Forward clutch worn out.

Oil pressure is low.

First reverse brake worn out from friction.

Direct clutch friction

Automatic Transmission 2B2-31 Traveling Test Operate the vehicle in the D Range making sure to check that the gear shift point and the gear shift line meet.

Note: When doing the driving test, make sure to watch out for traffic. Think about safety and stay alert for hazards.

Main Evaluation Points

Gear Status 1®2 will not upshift 2®3 will not upshift Gear shift point is in poor condition

Probable presumed causes 1-2 shift valve sticking.

Solenoid No. 2 sticking Gear shift control system problem 2-3 shift valve sticking.

Solenoid No.1 sticking.

Gear shift control system problem.

1-2, 2-3, shift valve not working properly.

Gear shift control system problem.

Automatic Transmission 2B2-32 P Range test 1. Set up an inclined plank raised at one end with a 5° inclination angle. Drive the vehicle onto the inclined plank and stop. Move the gear shift select bar into the P range and set the parking brake. At this time, make sure that the vehicle will not move.

2. Do a similar test on the inclined plank with the vehicle pointing downhill instead of uphill.

3. Move the select bar from the P range to the other ranges and be sure that the vehicle will not move.

Shift lever Switch Inspection

p

1. Check to be sure that the starter starts and the engine begins to run in ranges P and N. Be sure that the starter will not turn in ranges D, 2, Land R. This indicates an OK status. In R range, be sure that the vehicle back up lights work. Also, check the reverse alarm buzzer to make sure it is working properly and will make a warning noise when backing up. If those features are not working properly, loosen the attachment bolt and then adjust the depth that the bolt enters the hole.

N

switch shaft arm

2. In the case where the procedure above does not improve the situation, take off the shift switch connector and move the gear shift select bar as directed in the following chart. Make sure to perform a continuity test using the guide in the chart.

Terminal 1 number Color

Switch Position p R N D 2 L

BlackRed

2

3

4

5

6

7

8

BlackYellow

Yellow

Red

Black

GreenRed

GreenWhite

BlueWhite

X

X

X

X

X

X

X

X X

X

X

X

Main Problems: Starter will not turn: snapping of wire between 1-2 or contact is not proper.

Back up lamp and reverse alarm buzzer both not working: snapping of the wire between 3-4 or improper contact.

2 and L ranges are not downshifting: snapping of the wire between 5-6 and 6-7 or improper contact.

D range will not upshift past 2 Range: ground connection between 6-AT Controller.

Gear fixed in L range: ground connection between 7-8AT controller.

Automatic Transmission 2B2-33 Adjusting the Select Lever 1 . Put the select lever in N range.

�

•

�

N

[Q)

�

[6 2. Loosen the adjuster nuts for the Select Cable Joints and then shift the switch shaft arm to the N range. p

N

switch shaft arm

3. Have the cable in a free condition and move the lower adjuster nut to the selector cable joint at the edge of the sur­ face. Then tighten up the upper adjuster nut with a spanner wrench.

Vehicle Speed Sensor Inspection Inspect the AT controller coupler terminal between 3-11 for resistance values.

EJ Q

3 Clear

Vehicle speed sensor resistance amount: 160-200 0

In the case of a vehicle speed sensor found not to be at the standard resistance amount shown above, measure the resistance of the coupler (2 poles).

In the case of the sensor not working, replace the non­ working sensor.

In the case of the AT controller not being at the standard value, perform a solid test when the vehicle is functioning normally. Between the AT controller and the vehicle speed sensor, there may be problems with the harness snapping, a harness wire that may be shorted, or the coupler not making contact properly.

Automatic Transmission 2B2-34 Throttle sensor Inspection

(D

®® @

Take the throttle sensor connector from the vehicle harness. Then, measure the resistance from the throttle sensor connector.

e

Accelerator Full open 1-3 Resistance Value (KO) 2-3 Resistance Value (KO)

2.5-7.5 3 or greater

Accelerator Full open When going from 2 to 3, the resistance should increase more than 1 KO with the accelerator in full open position.

Maintenance 1. Take off the carburetor assembly.

2. Insert a washer between the rod's thermal element and the stopper screw while they are still completely warm. At this time, make sure to check that there is space between the first idle cam and the throttle lever.

3. Idle screw should be warm. Open the throttle valve fully.

Then, make sure the idle adjust screw and the throttle lever have space between them.

4. Battery voltage should be going to Coupler 1 and 2. Connect tester to Coupler 2 and 3. Then measure the generated volt­ age. As an example, if the measurement shows battery volt­ age of 13%, this equals a reading of 13 volts. Generated volt­ age should be 1.69. This would indicate that the throttle sensor needs servicing.

Reference:

When generated voltage rate is 13% with the throttle totally closed, the voltage rate would be 87% with the throttle fully open.

5. Take off the washer that was attached in Step # 2 above.

6. Install the carburetor assembly.

7. Radiator hose should be kept sufficiently warm.

8. Adjust the idle. (Refer to Section 2D).

Automatic Transmission 2B2-35 Inspection of Shift Solenoid Take off the transmission shift solenoid harness coupler. Then connect the battery to the trans­ mission's coupler side.

Then check for unusual noises.

I Inspect the shift solenoid I

I

Coupler's white line connected to the battery. Repeat the ON-OFF test and listen for noise.

NO

I

I YES Use the same method as above in regards to the coupler black line.

I

I

YES

Normal

Shift Solenoid

NO

I

I Solenoid number 1 in poor condition I I Solenoid number 2 in poor condition

Harness color Vehicle harness

Coupler - Grommet

Number 1

light green/black

white

Number 2

light green/white

black

D Range Idle Up Adjustments 1. Warm up until the radiator upper hose gets hot.

2. Inspect the carburetor link mechanism and the smoothness of the valve functioning.

3. Do a D Range shift.

4. Turn the D range idle up adjuster screw. Adjust the number of rotations to the normal recommended level.

Idle up RPM: 1100 ± 50 rpm Note:

Do these procedures with two people.

Make sure that the front and back wheels are completely blocked off. Keep the foot brake pedal held down.

Be careful that the car does not move or roll away.

Automatic Transmission 2B2-38 Troubleshooting (AT Controller) In this place, we will explain how to diagnose problems with the AT Controller.

Flow chart

1 . Gear shift in poor condition.

1. D Range shift setting in poor condition.

2. 2 Range shift setting in poor condition NORMAL

NORMAL

'f

'f

There is some gear shift functioning.

There is no gear shift functioning.

,,

NORMAL

NORMAL

'f

Inspect shift lever switch.

Refer to 2B-32

Adjust or replace BAD the slot lever "' sensor ,J

,,

NORMAL

,,

NORMAL

,, BAD

Inspect shift solenoid (refer to 2B-35)

,,

NORMAL

I

Adjust or replace the shift lever switch.

Inspect the vehicle BA� Replace the vehicle speed speed sensor ,. sensor Wiring failure and (refer to 2B-33) snapping ground problem

Inspect slot sensor (refer to 2B-34)

,,

BAD .....

1----.-i '

AT controller exchange

I

..... ,

Shift solenoid exchange

Automatic Transmission 2B2-39 2. L Range shift poor condition

L Range shift setting in poor condition

,�

First gear situation

NO

,

.....

Vehicle Speed

o km/h

YES 'f

Bring Vehicle speed up to 35 km/h 'f

'f

First gear situation

NO

,

"'-

YES

Shift lever switch inspection NORMAL

'�

BAD

..... Adjust or replace the

,,

i

Shift Solenoid inspection

BAD

i

Normal

AT Control replacement

3. R Range Shift Poor condition L Range shift setting in poor condition

,�

First gear situation iYES

Normal

NO

... ,

Transmission Poor condition

.....

,,

shift lever switch.

Replace Shift Solenoid

Analysis

Automatic Transmission 282-40

Notes regarding Analysis of the Assembly and Internal Workings Because of the Automatic Transmission, vehicles are composed of precision made parts.

Please be careful when doing analysis and assembly not to damage the precision parts.

Please keep the following rules: Make sure analysis and maintenance is done in a clean and dust-free environment.

Make sure to put rubber mats on the work benches to avoid damage to the parts.

Do not use rags or gloves. Use paper towels or towels made from nylon cloth.

When analyzing the case joint, please do not use a screw driver as a wedge to try to open the case. Instead, use a plastic hammer and use gentle taps.

Before doing analysis, make sure to wash out the dirt. Do not let dirt or other foreign objects enter into the transmission.

Clean parts with kerosene or ATF and wash them thoroughly. Make sure oil passage is not clogged by using the air blow test. (Use ATF or kerosene. Do not let any splash into your eyes or face). However, only disks, brake pans, resin washers, and rubber parts should be washed with ATF. Gasket, oil seal and 0-ring should be exchanged for new.

Make sure that ATF is applied to the sliding or rotating parts When preparing a new disk or new brake band, soak them first in ATF at least two hours before.

Do not use oil and grease unless you are certain they are a well-know brandname

Inspection and Treatment of Parts Item

Inspection content cast metal part & Machine prosmall marks, scratches, burrs, cessed or tooled parts. body damage, deep marks, grooves, oil passage clogged, marks on the surface of the attachment face, gasket remnants, cracks Bearing Inspection Will not turn smoothly.

Pitching, mark, cracking Bushing, thrust washer Inspection Marked or worn out Oil seal, gasket inspection See if the oil seal is marked or scratched up.

Material very hard.

Seal ring perimeter and side surface worn out, Gear type Inspection Mark or burr Spline Inspection Snap ring inspection Screw Inspection Spring Inspection Clutch disk, brake disk inspection Clutch plate, brake plate inspection Seal face inspection

Teeth worn out Dented, twisted Worn out or burred Shape changed Burr present Damaged Burned out, scarred, marked Worn out; burned; bent; clutch strained; damaged with nail Burned; worn out; strained; Damaged with a nail Mark; non-smooth surface Biting into foreign object

Treatment Take off small marks with an oil stone; Clean clogs with air or wire; Use an oilstone .

Exchange Exchange Exchange Exchange Exchange Exchange Exchange Repair with an oil stone or Exchange Exchange Repair with an oil stone.

Exchange Repair with an oil stone.

Exchange Repair with an oil stone.

Exchange Exchange Exchange Exchange Exchange Repair

. .

Automatic Transm1ss1on 2B2-41 Transm·iss1on Assembly 5

.__ t_ .:

Screw Torque (kg-cm)

1.

2.

3· 4.

5.

Automatic transmiss1on . assembly Dr�ve plate flange Drive plate Drive rear plate Torque converter

Automati c Transmission 2B2-42

Transmission Case Assembly

7

8

�,

/�

Screw Torque (kg-cm)

1.

2.

3.

45.

6· 7.

a.

Transmission case assembly Breather plug Torque converter hous· g Extension case m Extension case gasket Dust cover Extension case o·1I seal Cap

Automatic Transmission 2B2-43 Oil Pan Assembly 8

L

®

0:

Screw Torque (kg-cm)

1.

2.

3.

4.

5.

6.

7.

8.

9.

Oil pan Oil pan gasket Oil cleaner magnet Drain plug Oil level gauge Oil level guage O-ring Solenoid wire harness Solenoid wire harness plate

Automatic Transmission 2B2-44 Second Brake Assembly

HYDRAULIC SERVO

1.

2.

3.

4.

5.

6.

7.

Second brake band assembly Brake band pin Piston rod Brake rod washer Piston rod spring E ring Second brake piston

8.

9.

10.

11 .

12.

13.

14.

15.

Piston seal Piston seal ring Piston return spring Piston cover Piston cover O-ring Piston cover snap ring Piston cover with solenoid Snap ring

Automatic Transmission 2B2-45

Manual Shift Assembly

_.t : Screw torque (kg -cm)

L--__

1.

2.

3.

4.

5.

6.

7.

8.

Manual shift shaft Spacer Manual shift lever Spring pin Cotter pin Washer Oil seal Parking lock rod

9.

1O. 11.

12.

13.

14.

15.

Manual shift lever rod Parking lock ball bracket Manual detent spring Parking lock ball Ball shaft Spring Manual shift lever

Automatic Transmission 2B2-46

Direct, Forward Clutch Assembly

1.

2.

3.

4.

5.

6.

7.

8.

9.

Input shaft Input shaft seal ring Input shaft bearing race Input shaft bearing Input shaft bearing race Direct clutch assembly Direct clutch plate Direct clutch plate Direct clutch flange 10. Clutch plate snap ring

11.

12.

13.

14.

15.

16.

17.

18.

19.

Direct clutch drum Direct clutch piston Inner O-ring Outer O-ring Clutch return spring Return spring seat Clutch plate snap ring Direct clutch Number 1 washer Direct clutch Number 2 washer 20. Forward clutch disk

21.

22.

23.

24.

25.

26.

27.

28.

29.

Forward clutch plate Forward clutch flange Forward clutch cushion plate Clutch plate snap ring Forward clutch piston Inner 0-ring Outer O-ring Piston leader spring Return spring seat 30. Spring seat snap ring

Automatic Transmission 2B2-47

Direct, Forward Clutch Assembly

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

Front planetary ring gear Ring gear flange Ring gear snap ring Ring gear race Ring gear bearing Ring gear race Ring gear race Front planetary gear assembly Front planetary gear bearing Front planetary gear race Planetary sun gear Sun gear input drum Input drum snap Number 1 ring Input drum snap Number 2 ring Planetary thrust washer Rear planetary gear assembly Rear planetary ring gear Ring gear snap ring Rear ring gear race Ring gear bearing

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

34.

35.

36.

37.

38.

39.

Ring gear bearing Ring gear race Rear planetary gear thrust washer Rear ring gear bearing Ring gear bearing race Ring gear bearing race One way clutch assembly One way clutch One way clutch race One way clutch snap ring One way clutch snap ring First• Reverse brake flange First• Reverse brake disk First• Reverse brake plate First• Reverse brake damper plate First• Reverse brake piston First• Reverse brake piston Piston Inner O-ring First• Reverse brake return spring Return spring snap ring

Automatic Transmission 2B2-48

Output Shaft Assembly

2

1 . Output shaft 2. Output shaft seal ring 3. Parking lock gear 4. Snap ring 5. Speedometer drive gear 6. Sawclip 7. Speedometer driven gear 8. Bushing 9. Washer 10. Oil seal

Automatic Transmission 2B2-49

1

Transmission Unit Analysis 1. Pull out the torque converter.

2. Remove the bolt. Take off the car speed sensor.

1. Torque converter 1. Shift lever switch

3. Take off the manual shaft lock nut. After taking off the shift select bar, take off the shift lever switch.

4. Remove the attachment bolt from the oil filler tube.

T hen pull out the tube. T he tube should be lifted out in an upward direction.

1. Oil filll tube 5. Take off all 6 bolts and remove the case housing with a plastic hammer.

Note:

Make sure that the joint surface of the case has not been damaged by the driver.

1. Case hou ing 6. Take off the seven bolts and remove the exten­ sion case.

1. Extension case

Automatic Transmission 2B2-50 7. Speedometer drive gear & parking lock gear should be removed in the following order: 1. Snap ring 2. Speedometer drive gear 3. Snap ring 4. Snap ring 5. Parking lock gear

(i)

@

®

1. Second brake band pin 8. Pull out the second brake band pin.

Note: Remember the chamfer direction.

9. Remove the 8 bolts from the oil pump. Use a special tool and remove the oil pump.

Special Tools:

(A) Oil pump remover: 09918-48211 (B) Oil pump remover attachment: 09918-48220

Note : The oil pump's front surface should be pulled

1. Oil pump

Input shaft Direct clutch Forward clutch

out in an upward direction.

The oil pump cover 0-ring should be removed from the housing. Then the oil pump can be removed. The oil pump should be shaken and twisted while it is being removed.

10. Remove the direct clutch and the input shaft.

Note : Be careful not to mix up the order of the ring

gear race and the bearings attached to the for ward clutch. When the unit is taken apart, be sure to keep the pieces safely together in the appropriate order.

Automatic Transmission 2B2-51 11. Remove the second brake band.

Note:

When the second brake band is opened, it is easy to get a crack in the facing. It should be kept together with a wire.

12. Remove the front planetary ring gear.

Note : Be careful not to mix up the order of the ring gear

race and the bearings attached to the front plane tary ring gear. When the unit is taken apart, be sure to keep the pieces safely together in the appropri ate order.

1. Front planetary ring gear 2. Front planetary gear assembly

13. Remove the front planetary gear assembly.

1. Sun gear 2. Front planetary gear assembly

14. Remove the planetary sun gear and sun gear input drum.

1. Planetary sun gear

15. Remove the one- way clutch snap ring

Automatic Transmission 282-52

16. Remove the one way clutch, rear planetary gear and the output shaft.

2

3

1. One way clutch 2. Output shaft 3. Rear planetary gear

17. Remove the first reverse brake snap ring. Then remove the flange, the disk, the plate, and the cushion plate.

1. Snap Ring

18. Use a special tool to push the piston cover and take off the snap ring and then remove the second brake piston.

Special tool: (A): Valve lifter: 09916-14510 Note:

Do not push the piston cover any more than necessary.

Push the center of the piston cover.

1. Second Brake Piston Cover

19. Take off Bolt 15. Then use a plastic hammer to pound around and remove the oil pan.

Note:

Do not insert any object such as a screwdriver into the oil pump joint surface.

Automatic Transmission 2B2-53 20. Remove the oil pan gasket.

Note:

Completely remove the gasket that is attached to the joint surface.Make sure there are no small pieces of the gasket loose inside the mechanism. Keep all parts clean.

1. Scraper 21.

Takeoff the five bolts and remove the oil strainer.

At this time, the solenoid coupler two pieces can be removed.

22.

Pull out the cotter pin from the manual valve side .

Then remove the manual valve links.

1. Oil Strainer 2

3

1. Cotter pin 2. Manual valve 3. Manual valve links 23. Take off the 12 bolts and remove the valve body..

1. Accumulator piston 2. Oil hole

24.

Use an air gun to blow air through the oil passage.

(The compressed air pressure should be about 1 kg/sq. cm). Then remove the accumulator piston.

Note:

The accumulator piston may blow out. The recom mended procedure is to put your hands on it.

Automatic Transmission 2B2-54 25. Pull out the parking lock ball shaft. Remove the parking lock pole.

1. Parking lock ball 2. Parking lock ball shaft

26. Remove the 4 Bolts. Then remove the manual detent spring and the parking lock ball bracket.

Detent spring Parking lock bolt bracket

2.

27. Use a drill to take off the manual lever collar caulking. Then pull the spring pin and pull the shaft out the shift lever side.

Then lift out the lever, the links, and the parking lock rod.

These pieces should be lifted straight out together and removed.

1. Cover 2. Shift lever

28. Use a special tool to push down the return spring and remove the snap ring.

(B)

Special Tools A. Spring compressor Number 1 set: B. Oil pump remover: C. Oil pump remover attachment:

(C)

4 1.

2.

3.

4.

Return spring Piston Snap ring Case

09926-98320 09918-48211 09918-48220

Note: Fix the oil pump remover shaft in a stable position.

Tighten up the nut side.

Do not push on the return spring any more than necessary.

Automatic Transmission 2B2-55 29. Blow air through the oil passage. Pull out the first reverse brake piston.

Note: Do not let the piston be positioned in a slanted orientation. Be sure to only blow the air through gently a little at a time, so the piston does not end up slanted.

If blowing air through the passage does not release the piston, it can be pulled out with pliers.

1. Piston 2. Oil Hole

30. Use a special tool to pull out the oil seal.

(B)

Special Tools

(A) Rotor remover slide shaft: (B) Bearing remover:

(A)

09930-30102 09921-20201

Automatic Transmission 2B2-56 Subassembly Analysis Oil Pump Assembly

3

Tightening torque (kg w cm)

1.

2.

3.

4.

5.

6.

7.

8.

9.

Oil pump body assembly Oil pump body oil seal Oil pump cover O-ring Inner Gear Outer gear Oil pump cover Oil pump cover seal ring Oil pump gasket Seal

Automatic Transmission 2B2-57 Analysis 1. There are 5 bolts that should be taken off. Then take off the oil cover. Then remove the outer and the inner gears.

2. Take off the oil pump cover O-ring.

1. Bolt 2. Oil Pump Cover

Inspection 1. Make sure to check for damaged and worn seal rings and bushings.

2

1. Seal ring 2. Bushing 2. Measure the outer gear body clearance with a thick­

ness gauge.

Clearance:

Standard amount:

Limits:

.08- .15 mm .30 mm

1. Outer gear

3. Measure the inner gear and the outer gear chip clear­ ance with a thickness gauge.

Clearance:Standard amount:

Limits:

1. Inner gear

.13- .20 mm

0.30 mm

Note: Make sure to do the measurements when the torque converter is attached.

4. Measure the inner gear, the outer gear and the pump

body for side clearance.

Clearance:

Standard amount:

Limits:

.02- .05mm

0.1

mm

Automatic Transmission 2B2-58 Installation The installation procedure is exactly the opposite of the dis­ assembly procedure. Be sure to be careful about the follow­ ing points: When the inner gear and the outer gear are attached to the pump body, make sure to apply ATF to the gears first.

When attaching the pump cover, make sure not to damage the oil seal. The spline can scrape or damage the oil seal.

Please be careful.

Use the standard tightening torque when tightening the pump body.

Tightening torque: 65 - 95 kg-cm When attaching the O-ring and the oil seal, make sure that there is sufficient ATF applied and that they fit properly in their grooves.

After the O-ring and the oil seal are attached, make sure that the inner gear rotates smoothly. At this time use a torque converter to check the rotation.

Note:

When attaching the oil pump, and attaching bolts in the bolt holes, be careful that the bolts fit well. The bolts with double-cut tops and ridged slices on the sides need to match up well with the machine holes.

Automatic Transmission 2B2-59

Direct Clutch Assembly

2

1.

2.

3.

4.

5.

6.

Direct clutch washer Direct clutch drum Inner 0-ring Direct clutch piston Outer 0-ring Clutch return spring

7. Return spring seat 8. Spring seat snap ring 9. Clutch plate 10. Clutch plate 11. Clutch flange 12. Clutch plate snap ring

Automatic Transmission 2B2--60 Analysis 1. Take off the snap ring. Then take off the clutch flange and the clutch disk.

2

Note:

Snap ring Direct clutch assembly

Before performing the analysis, measure the height of the snap ring and the flange.

Make sure to check to see if they are within the standard value range. ( Refer to 28-61)

2. Use a special tool to push down the spring seat and then take off the snap ring.

Note: spring sheet snap ring

Do not push the spring seat down any more than necessary.

Specialtool: (A): Spring Compressor 09926-98330

3. From the oil passage use an air gun to blow air. Make sure that the other holes are closed. T hen take off the piston.

1. oil hole 2. air gun 4. Take off the 0-ring.

1. Outer 0-ring 2. Piston

Automatic Transmission 282-61 Inspection and Maintenance Make sure to check that the check ball is able to move freely.

Blow air and check the check valve to be sure that it is not clogged up.

1. Piston

2. Check valve

Installation The installation procedure is exactly the opposite of the disassembly procedure. Be sure to be careful about the following points: Inner and outer O-ring should be replaced with new parts.

Install the ATF application.

1. Piston When the piston is inserted into the clutch drum, make sure that the O-ring does not get twisted or come off.

You need to be especially careful on this point.

Make sure that the C-ring fits into the spring seat of the four projections.

The clutch disk and the clutch plate need to be put in the proper order. Be certain not to mix up the clutch disk and the plate. clutch (Plate®Disk®Plate®Plate®Disk) 1. Projection

When the new clutch disks are installed, be sure to soak them for at least two hours in ATF. Measure the height of the snap ring and the clutch flange.

Snap Ring Height: 2.53-3.06 mm Even when a new clutch and new plates are installed, they still may not be within the standard range. Follow the thickness of the clutch flange when making a selection of replacement materials.

Spare clutch flange thickness:

3.30 mm 3.33 mm 3.51 mm

Automatic Transmission 2B2-62

Blow air through the oil drum passage and make sure that the piston will move.

1. Oil hole

Automatic Transmission 2B2-63

Forward Clutch Assembly

1.

2.

3.

4.

5.

6.

7.

8.

Direct clutch washer Input shaft bearing race Input shaft bearing Input shaft bearing race Input shaft seal ring Input shaft Inner 0-ring Forward clutch piston

9.

10.

11.

12.

13.

14.

15.

16.

17.

Outer 0-ring Piston return spring Return spring seat Spring seat snap ring Clutch plate Clutch disk Clutch cushion plate Clutch cushion flange Clutch plate snap ring

Automatic Transmission 2B2-64 Analysis 1 . Remove the clutch plate snap ring and the flange, disk, plate, and cushion plate.

Flange Disk Plate Cushion plate

Note: Make sure to remember to follow the cushion plate direction.

2. Use a special tool and take off the snap ring.

Special Tool: (A) Spring compressor: 09926-98330

3. From the input shaft's oil hole, blow air through and take off the piston.

1 (top side of opening) 1. Oil hole Check valve Be sure that the check ball moves freely.

Blow air through and then check to see if the check valve is clogged up.

Automatic Transmission 2B2-65 Installation

1.

2.

3.

4.

Flange Disk Plate Cushion plate

The installation procedure is exactly the opposite of the disassembly procedure. Be sure to be careful about the following points: Inner and outer O-ring should be replaced with new parts.

Install the ATF application.

When the piston is inserted in the clutch drum, make sure that the O-ring does not get twisted or come off. You need to be especially careful on this point.

The dumper plate should be attached like a dish.

Make sure that the C-ring fits into the spring seat of the four projections.

The clutch disk and the clutch plate need to be put in the proper order. Be certain not to mix up the clutch disk and the clutch plate.

Measure the height of the snap ring and the clutch flange.

2

Snap Ring Height: 2.01-2.68 mm Even when a new clutch and new plates are installed, they still may not be within the standard range. Follow the thick­ ness of the clutch flange when making a selection of replacement materials.

Spare clutch flange thickness:

1. Snap Ring 2. Flange

3.30 mm 3.33 mm 3.51 mm

Automatic Transmission 2B2-66 Valve Body

10-1

s--<O,

,a-Q

1.

2.

3.

4.

5.

6.

7.

Upper Valve Body Valve Body Gasket Number 1 Valve Body Plate Valve Body Gasket Number 2 Lower Valve Body Oil Strainer Accumulator Forward Clutch Piston

8. Upper 0-Ring 9. Lower 0-Ring 10. Accumulator Return Spring 11. Accumulator Second Brake Piston 12. Upper 0-Ring 13. Lower 0-Ring 14. Accumulator Return Spring

Automatic Tran smission 2B2-67 yl ��s IS!.________ ln s ectio n An n�a� _____.:.:.: ::..: --= p__

1 Lower Valve Body 2: Pressure Reg lator Valve � 3 Pressure Reg lator Valve Plunger 4: Plate Wa�her 5 Valve Spring 6: Valve Sleeve 7. Ring 8. Manual alve 9. Low Cost 'It Modulator Valve 1 0. Modulator Valve Spring 11. Plug

12.

1 .

14.

3 15.

16.

17_ 18.

19· 20.

21.

22.

Ke

i Shift Valve ��ift Valve Spring Plug Key Ball Spring Bracket 2-3 Sh"ft I Valve Shift Soleno�"d Number 1 Shift Soleno1 d Number 2

Automatic Transmission 2B2-68 Analysis Procedure Warning When pulling the upper body from the lower body, lay the upper body down on its lower side.

In the event of clutch and brake burnout, you have to per­ form control valve maintenance and analysis.

2 1. Steel ball

2. Upper body

Inspection and Maintenance Valve body gasket, plate Check the gasket for damage or swelling..

Check for damage to the plate.

Make sure to check that the plate orifice is not clogged. If it is clogged, use the air blow- through treatment.

2 1. Orifice 2. Plate

Control Valve Check to see that each valve is moving smoothly.

Each valve should be checked for damage or for foreign objects that may have become stuck in them.

1. Manual valve

Caution regarding Assembly

3 4

5 6

1.

2.

3.

4.

5.

6.

Upper body Gasket Number 1 Plate Gasket Number 2 Lower body Strainer

Assembly is the reverse order of the steps in analysis.

When attaching the valve, make sure that ATF is applied first.

The valve body strainer should be washed completely and then dried with an air gun.

Do not use the waste.

Be careful when assembling the gaskets not to mix them up.

Gasket number 1 should be on the upper body side.

Gasket number 2 should be on the lower body side.

Automatic Transmission 2B2-69 Upper Body Attachment Use two reamer bolts to temporarily hold position.

Tighten the bolts in diagonal order.

Use a limit wrench to tighten to standard torque.

Number CD

Type

1

Reamer Bolt

2

Regular bolt

3

Regular bolt

Length from Neck to Base (mm)

23 23 18

Tightening torque: 52-58kg-cm Attach the lower body.

Tighten the bolts in diagonal order.

Use a limit wrench and tighten to standard torque.

Number

Type

1

Regular bolt

2

Regular bolt

3

Regular bolt

Length from Neck to Base (mm)

Tightening torque: 52 - 58 kg · cm

38 30 23

Automatic Transmission 2B2-70 Second Brake Inspection Second Brake Band Perform a general visual inspection of the second brake band and look out for bands that may be damaged, worn out or changed from the original color. All of these need to be replaced.

Note:

New second brake bands should be soaked at least two hours in ATF before they are used.

Second Brake Piston The piston seal ring should be checked for damage.

Perform a visual inspection of the transmission case piston bore. Look for damage or signs of worn out parts.

1. Piston seal ring 2. Piston bore

Input Shaft Inspection

0

Perform a visual inspection of the spline. Watch for damage or signs of worn out parts.

Perform a visual inspection of the seal ring. Watch for damage or signs of worn out parts 1. Seal ring

Planetary Gear Inspection Inspect each gear and check to see if there is damage, color change, noise, and smoothness.

Automatic Transmission 282-71

Planetary ring gear Inspection The gear teeth surface should be given a general visual inspection and checked for damaged or worn out parts.

Parking lock pole Inspection Check for damage or signs that the parking lock pole may be worn out.

Bearing Inspection Turn the bearing with your hands. Check to see if there are jagged places. Check for noise and smoothness of rotation.

Automatic Transmission 2B2-72 Assembly Method 1. Oil Seal Use a special tool to pound the oil seal.

Special Tool: (A) Bearing Installer: 009943-8821 (A)

2. Attach the manual shift shaft receiver and pound the spring pin. Then turn the collar 90°and tighten it up. The concave side should fit snugly

3

1. Claw 2. Shift lever 3. Washer

Notice: The shaft should be inserted on the shift lever side.

Attach washers to the front and the back. ( The pur pose is to avoid damage to the oil seal.)

3. Attach the manual detent spring and the parking lock pole bracket.

2 1. Manual detent spring 2. Parking lock ball bracket 4. Attach the accumulator piston's O-ring. Be sure to apply ATF when attaching.

1 . Accumulator piston 2. O-ring 5. Attach the parking lock pole. Move the manual shift lever and then make sure that the parking lock pole moves smoothly.

1. Parking lock ball 2. Parking lock ball shaft

Automatic Transmission 2B2-73 6. Attach the first reverse brake piston.

Replace the piston outer O-ring and inner ring with new parts. Be sure to apply ATF first before installing.

Insert the brake piston in the case with the spring hole in the upper direction.

(C) 4 (A)

1.

2.

3.

4.

Return spring Piston Snap ring Case

Notice: Be careful that the O-ring is not bent, twisted or broken and does not come off.

Use a special tool to push up the return spring assembly. Attach the snap ring.

Special tools (A) Spring Compressor Number 1 Set: 09926-98320 (B) Oil Pump Remover: 09918-48211 (C) Oil Pump Remover Attachment: 09918-48220

7. Attach the output shaft. Attach the Race (1) to the case side.

Apply grease to the bearing and the Race (2) and then, attach the bearing and the Race (2) to the output shaft side.

<D

Internal diameter (mm)

1 . Output shaft 2. Bearing

External perimeter (mm)

Race (1)

19

32

Bearing

20.9

32

Race (2)

21.1

32.2

Flange Inner diameter of Flange

Inner diameter of Flange

8. Use Suzuki Super Grease C on the thrust washer. Fix the rear planetary gear into a stationary position. Then insert the rear planetary gear.

1. Thrust washer

9. First reverse brake, dump plate, plate, disk and flange should be attached to the case in that order.

The dump plate's converse side should be raised up and attached.

The plate, disk, and flange should be attached in that order.

Fix the snap ring into a stationary position. ��;¥-m'j--3

1. Disk 2. Flange 3. Plate

Notice: When first using newly installed disks make sure to soak them at least two hours in ATF. Do not forget to attach the snap ring.

Automatic Transmission 282-74 Blow air through the oil hole. Then check to see if the brake pistons are able to move or not.

2

1. Oil hole 2. Piston Measure the gap between the snap ring and the flange.

Standard Gap: 0.65-1.94 mm

If the gap is not within the standard value range, replace the first reverse brake disk with new parts.

10. Turn the rear planetary gears clockwise and then push in the one

way clutch until it fits in the groove.

Note:

When the planetary is rotated in the right direction, the rota tion will be smooth. When the planetary gear is rotated in the left direction, it will be locked.

When the planetary gear is turned to the left, the one way clutch will go in easily.

1. One way clutch 2. Planetary gear

11. Attach the solenoid harness.

1 . Solenoid harness

Automatic Transmission 2B2-75

12. Attach the valve body.

Tighten the reamer bolts lightly.

Use a limit wrench to tighten all the other bolts in diagonal order.

4

Tightening torque: 80-120 kg-cm 5

Number

Type

Length from Neck to Base (mm)

1

Reamer bolt

31

2

Regular bolt

45

3

Regular bolt

39

4

Regular bolt

31

5

Regular bolt

25

13. Attach the oil strainer: Tightening torque: 52 - 58 kg -cm

1. Oil strainer 14. Attach the oil pan. Attach the magnet right under the oil strainer.

2

1. Oil strainer 2. Vent 3. Magnet Attach the bolt with the standard tightening torque.

Tightening torque: 40 - 60 kg -cm

The oil pan drain bolt should be tightened to a standard tightening torque.

Tightening torque: 180 - 270 kg -cm

1. Drain Bolt

Automatic Transmission 2B2-76 15. Attach the sun gear.

To prevent the thrust washers from falling off, it is advised to use Suzuki Super Grease C on them when installing them. The thrust washer projections should be matched up with the holes in the sun gear.

Note:

Before inserting the sun gear, the rear gear race should be matched up at the center.

1 . Projection 2. Hole 16. Attach the front planetary gear.

Bearings and race need Suzuki Super Grease C. The planetary gear (lower part) should be fixed in a stationary posi­ tion.

Internal Diameter (mm) 3

1. Front planetary gear 2. Bearing 3. Race

Bearing

24

Race

22

External Perimeter (mm)

37.2 37.2

17. Attach the front planetary ring gear. The gear race (1) requires AT oil. Then the race may be attached to the upper portion of the planetary gear.

Race (2) and bearings need Suzuki Super Grease C. Then attach the lower portion of the ring gears. Ring gear attaches to the planetary gear.

2

1. Front bearing gear 2. Bearing Internal Diameter (mm)

External Perimeter (mm)

Race (1)

14

27.9

Bearing

17.2

29

Race (1)

17

30.9

Automatic Transmission 2B2-77

18. Second brake band, band pin Note:

"

When attaching the band pin, notice that there are cut corners. The cut corners should be placed in the front.

Band pin

[I

front

)>

---+

cut corner

19. Attach the direct clutch to the input shaft. Place Suzuki Super Grease Con the washer and the washer projections and the con­ cave surface of the direct clutch.

Note:

There is a groove on the washer that indicates the part that is meant to be the top side. The groove is gold colored.

1. Washer

The teeth of the direct clutch mesh with the input shaft and the direct clutch is inserted into the input shaft.

1. Input shaft 2. Direct Clutch

20. Ring gear race & bearing

race (1) 1. Forward clutch 2. Bearing 3. Ring gear

Apply AT oil to the race (1) and then attach to ring on right side.

Apply Suzuki Super Grease C to bearing and race (2). Then attach to forward clutch side Internal Diameter (mm)

External Perimeter (mm)

Race (1)

14

28.7

Bearing

17.2

29

Race (2)

17

30.9

21 Attach the input shaft and direct shaft. Open up the second brake band. Insert input shaft with direct clutch. Insert and turn.

Note: 1. Input shaft 2. Direct clutch

When attaching the input shaft, be careful not to drop the bearing and the race.

Be careful that those items do not bite into the output shaft seal ring.

Automatic Transmission 2B2-78 22. Attach the input shaft bearing and race. Apply ATF to bear­ ing and race with flange.

Bearing race (1) has the flange attached. Attach bearing race (1) to the input shaft.

1. Bearing Race (2)

Internal Diameter (mm)

External Perimeter (mm)

Race (1)

19

32

Bearing

20.9

32

Race (2)

22.3

35

Flange Inner Diameter of Flange -None

Put Suzuki Super Grease Con the other bearing race (2) with­ out the flange. Then attach on the oil pump side.

23. Attach the second brake piston following the inspection.

The head of the piston cover should be opened with JE 5 holes using a drill .

Use this piston cover head as a special tool. Attach calipers to the piston rod head.

Then blow air in the oil hole. Then measure the piston rod stroke.

2

1. Piston cover 2. Piston 3. Piston load

Piston rod

The second brake piston rod stroke: 1.5-3.0 mm.

In the case of non-standard volume, exchange the second brake band or a different length piston rod.

Piston Rod Selection Distinguishing Mark

Length (mm) 81.3 82.5

Distinguishing Mark no mark 1 ridge or groove.

Automatic Transmission 2B2-79 Take off the piston cover with the hole. Apply Suzuki Super Grease C to the C-ring.

That C-ring fits into the ring groove. Then the brake pis­ ton should be inserted into the case.

1. 0-ring 2. Seal ring 3. Piston cover 4. Piston 5. Piston rod

Note:

Make sure that the piston rod completely fits into the brake band rod.

Apply AT oil to the piston cover O-ring. Use a special tool to attach the piston cover to the case.

Special Tool: (A) Valve lifter: 09916-14510 Second brake piston cover

24. Apply Suzuki Super Grease C to the direct clutch

washer. Then match and attach the oil pump body's notch to the direct clutch washer.

Note:

1. Seal ring 2. Direct clutch washer

Suzuki Super Grease should be applied to the seal ring. Then make sure that it fits into the groove. When attaching the oil pump, do not let the oil pump bite into the seal ring.

25 Exchange the oil pump cover O-ring for a new one.

Be careful not to let the input shaft bearing race and direct clutch drop. Then attach the oil pump to the case.

Tightening torque: 65 - 95 kg -cm

26. Attach the parking lock gear and the speedometer drive gear.

Note:

3

1. Speedometer drive gear 2. Parking lock gear 3. Snap ring

Do not forget that there are three snap rings.

Automatic Transmission 2B2-80 27. Attach the extension case.

1. Extension case 28. Case Housing Apply Suzuki Three Bond 1215 to the case housing's 6 attachment bolts and attach them to the designated area.

Use the recommended tightening torque below to tighten them up.

Suzuki Three Bond 1215: 99000-3108-15A Tightening torque: 160 - 230 kg -cm

1. Case housing 29. Measure the thrust direction play of the input shaft edge surface.

Input shaft thrust play: 0.3 - 0.9

When the play measurement is found to be outside of the standard range, take off the oil pump. On the oil pump side there is the input shaft bearing race. Depending on the thickness of the race, exchange.

Input shaft bearing's pair of race: 0.8 . 1.2 mm 30 Attach the speed sensor.

31 Attach the torque converter.

Note:

Case housing

When attaching the torque converter, you need to be careful not to damage the oil pump's oil seal.

Make sure to check that the torque converter fits completely into the transmission.

Strategy for checking above items: From the case housing edge surface to the drive plate attachment use a standard size (A) for mea surement purposes.

Standard size (A): 28 mm or more Make sure that the torque converter turns smoothly.

Apply grease to the torque converter centerpiece.

Use Suzuki Super Grease A: 99000-2501O

Automatic Transmission 2B2-81 Thrust Bearing, Race Installation Schematic Diagram

Front

9

1.

2.

3.

4.

5.

6.

7.

8.

10

Input shaft bearing, race Front planetary ring gear bearing, race Front planetary ring gear bearing, race Front planetary ring gear bearing, race Rear planetary ring gear bearing, race Rear planetary ring gear bearing, race Input shaft Oil pump

13

9.

10.

11.

12.

13.

14.

15.

16.

Direct clutch Forward Clutch Front planetary gear Sun Gear One Way clutch First/ Reverse Brake Rear planetary gear Output shaft

Automatic Transmission 2B2-83

Maintenance Material List Material AT Oil

Grease

Genuine Part

Use AT Oil

Suzuki ATF 5D06 (99000-22810)

Suzuki Super Grease A

Select Assembly Oil Seal Lip Torque Converter Center Piece

Suzuki Super Grease C

The grease maintains the thrust bearings and the bearing race.

Case Housing

(99000-25010)

(99000 - 25030)

Sealant

Suzuki Three Bond 1215 (99000 -3108 -15A)

Special Tools

09918 - 48211 oil pump remover

09918 - 48220 Oil pump remover attachment

09925 -37810 ATM Oil pressure gauge

09921 -20120 Bearing Remover (0 12 )

09926 -98320 Spring Compressor Number1 set

09926 - 98330 Spring Compressor Number2